Apparatus for felting fibrous materials.



' E. MQKNIGHT. APPARATUS POR FELTING PIBROUS MATERIALS Patented Oct. 18,1910.

APPLICATION TILED OCT 22, 1909. 973,280.

3 SHEETS-SHEET 1.

llllllllllllllllllnml rm: NORRIS PETERS co., WASH/Nam", a c.

E. M. KNIGHT. APPARATUS FOR FELTING FIBROUS MATERIALS APPLICATION FILED 001. 22, 1909.

' Patented Oct. 18,1910.

3 SHEETS-SHEET Z.

IIIIIIIIIIHIIHHIH E. M. KNIGHT. APPARATUS FOR FBLTING FIBROUS MATERIALS. APPLIOATIOH FILED DOT. 22, 1909.

973,286. Patented Oct. 18,1910.

3 SHEETS5HEBT 3.

my NORRIS PETERS co., WASHINGON, o. c.

APPARATUS FOR FELTING FIIBROUS MATERIALS.

To all whom "it may concern:

Be it known that T, EDWARD M. KNIGHT, a citizen of the United States, residing at New York, in the borough of Manhattan and State of New York, have invented certain new and useful Improvements in Apparatus for Felting Fibrous Materials, of which the following is a specification.

This invention relates to an apparatus designed particularly for the manufacture of felt, or pads for filters acting, preferably, under direct pressure from the main, although other types of filters may be supplied with such pads, or the felted material may be used for other purposes, the pads being found especially useful any in stance where it is desired to eliminate from liquid the contained impurities.

The invention consists, essentially, of a lower die and a series of upper dies operating successively to reduce a mass of fibrous material, as asbestos and to form alternate layers of the same with layers of nonfibrous material, as carbon or carbonaceous material, whereby the layers of the two materials are interstratified one with the other.

The invention also consists of the construetion and combination of parts which I will hereinafter describe and claim.

In the accompanying drawings forming a part of this specification and in which similar reference characters indicate like parts in the several views; Figure 1 is a sectional view of a lower die as employed in my in vention. Fig. 2 is a similar view showing the operation of the first of the upper dies. Fig. 3 is a sectional view of the lower die showing the use of the first of the tools employed when applying the non-fibrous coating. Fig. 4 shows the lower die with its contained material ready for the operation of the second upper die. Fig. 5 shows the operation of the second upper die. Fig. (3 shows the use of the second tool used in applying the non-fibrous coating. Figs. 7 to 11 inclusive are similar views showing successive operations of upper dies and tools similar to those shown in Figs. 2 to 6 in elusive. Fig. 12 is a broken plan view of one of the felted pads.

In said drawings A represents the lower die which in the present instance may be formed of any suitable material as cast or spun brass or other metal with a wooden or other core, said die having a portion, A, of

Specification of Letters Patent.

Application filed October 22, 1909.

Patented Oct. 18, 1910.

Serial No. 523,959.

reduced diameter at its upper side forming an annular shoulder a/iat a point about midway of the height of the die. This die has the metal portion extending upwardly over the sides and over the top of said core, while the portion above such shoulder is indented or otherwise provided with annular grooves Z) in which are secured the turned down or edge portions of a suitable fabric 0 which extends over the upper surface of the die and is designed to be moistened, for a purpose I will hereinafter describe.

Any suitable means may be adopted for securing the fabric, under tension, to the face of the die and over the sides thereof; one means which I have shown for the purpose comprises the employment of cords or wires, 1), which are passed tightly around the down-turned edges of the fabric, to thereby press the fabric into the grooves formed in the body portion of the die, said cords being secured by tying or in any suitable manner.

Extending vertically above the lower die is a rim or flange B preferably or annular form having its lower edge supported upon the shoulder a of the die; the inner wall of this rim engages the outer surface of the down-turned portion of the fabric with sufficient friction to hold the rim securely in place, but to permit it to be removed from the die upon the application of pressure. The rim extends a suitable distance above the top of the lower die and in the chamber thus formed is placed a mass of comminuted material, which material I prefer to be in the form of comminuted asbestos derived from a suitable carding machine.

In connection with the lower die, A, I employ a series of upper dies adapted to act successively and progressively upon different zones in the mass of material placed within the chamber formed in the rim, B. In Fig. 2 I illustrate the first of the series of upper dies and which die, G, has a diameter about equal to the interior diameter of the rim, B, said upper die having a central portion, D, of reduced diameter which projects below the under side of the die and is adapted to engage the central portion of the mass of material in the rim or holder, B, and compress this portion of said material without disturbing the remaining portion, with the result that the central portion of the said material is formed with a depressed chamber, E, the material at this point being strongly compressed to form one of the zones or layers of the completed article.

The central portion as well as the under side of the upper die, C, is covered by a strip of fabric, F, which is secured smoothly and tightly over the surface thereof ,by means of grooves, C 0 formed respectively in the circumference of said die and in the circumference of the central projecting portion thereof, and tying cords or other suitable securing devices. The fabric covered surfaces of both the upper and lower dies are designed to be moistened by water to prevent the fibers of asbestos adhering to said surfaces when brought in contact there with.

The mass of material having been subjected to the initial compression and provided with the central cavity, I now coat the depressed surface, or first zone, with a nonfibrous material, say a liquid charcoal or other carbonaceous substance, as shown at e, which quickly sets or dries and in order that this may be effected in a simple manner and without disturbing any portion of the carded material not yet compressed, I employ the tool, G, shown in Fig. 3, which tool consists of a tubular structure having a flared or funnel shaped upper end, G, and a cylindrical lower portion, G, of such diameter that it will fit uniformly within the depressed portion of the fabric produced by the operation of the central projection, D, of the first upper die, as shown in Fig. 2. The non-fibrous material, in a plastic or semiliquid condition and of any suitable composition is readily applied to the depressed floor of the chamber 6, by a brush or other means operating within the cylindrical portion of the tubular die, G, of Fig. 3.

"When the depressed floor or portion, 6, of the mass of material is thus coated or covered with the carbon or non-fibrous mate rial, the tool, G, is removed and the cavity previously formed by the central portion, D, of the upper die is now filled with a mass of carded asbestos or other loose fiber, after which the portion of the material imme diately surrounding the portion first compressed, is compressed by the second operating die, H, shown in Fig. 5. This die is also of such diameter that it will readily and more or less closely and uniformly fit within the rim, B, and it has an annular portion, h projecting from its under side between the center and circumference and surrounding a central opening H which corresponds substantially in size and shape with the depressed portion formed by the projection, D, of the first die.

The die, H, is covered with a suitable fabric, H, which extends over its entire inner surface and is designed to be moistened in the manner and for the purpose before described. I11 applying the fabric to a die similar to the one shown at H, a sheet of material is first applied over the inner face of the die and a metal plate, if, of a size which enables it to closely fit the depressed portion or chamber, H, of said die, is pressed into this chamber carrying the fabric with it until it is closely pressed against the bottom of the chamber, when the plate is secured by screws, 2', or other fastenings. The fabric is now drawn tightly at the edges and at one or more intermediate points by cords engaging in grooves, or otherwise, with the result that it is stretched evenly over the sides and bottom of the annular projecting portion h of the die; the outer edge of the fabric is secured by a cord or other suitable means engaging a groove or channel made in the circumference of the die as shown.

The projecting portion h of the die, H, is of slightly less depth than the projecting portion, D, of the first die, C; consequently the material immediately surrounding the depression made by the first die is not com pressed to the same extent that the middle portion of the material operated on by the first die is compressed, while the mass of loose carded asbestos, which has been placed in the depressed portion formed by the central part of the first die is undisturbed dur ing the operation of the die, H, because of the formation of the chamber in the central portion of the said die, H, and which chamber is designed to receive said mass of loose material when the die, H, is operated by any pressure applying means. It will be understood that each of the dies is subj ected to a suitable pressure which may be derived from any source, and that when the die, H, has been inserted and pressure applied to it as described, there will be formed in the original mass of fibrous material an annular depression corresponding to the part it of said die, H, as shown in Fig. 6. In order that this second depressed portion may receive a coating of nonfibrous material, as carbon or other carbonaceous filler, I employ the tool, I, shown in Fig. 6, which tool consists of inner and outer concentric walls, 2-3, and an upper flaring end, 4, said walls being spaced apart a distance equivalent to the width of the chamber or depression formed by the part, it, of the upper die, H, of Fin. 5.

The tool, I, is placed in the depression formed by the die, H, and the floor of the depression is coated with the non-fibrous material, or liquid carbon by simply manipulating a brush in the chamber or space inclosed by the inner and outer walls of the tool, I. The central portion of the tool, I, is closed on top, and is open below to admit that portion of loose material at the center of the pile of carded material, and which loose mass is intended to be undisturbed until the operation of a final tool as I will presently describe. Having coated the portion of the proposed pad operated upon by the die, H, the tool, I, is removed and the cavity made by the die, H, is filled with loose fibers of carded asbestos, as shown in Fig. '7.

In order that the remaining portion of the original mass of fiber may be compressed and the compressed portion provided with a strata or layer of non-fibrous material, or carbon, I employ the die, K, shown in Fig. 8, which die has a projecting annular portion inclosing an intermediate space whose diameter is about equal to the exterior diameter of the lower portion of the tool, I. In other words, the inner diameter of the depression formed in the center of the under side of the die, K, is sufficient to inclose the two masses of loose material which have been placed in the coated depressions formed by the dies C and H before mentioned. The die, K, having been applied as shown in Fig. 8 and subjected to pressure, the mass of material circumscribing the depression formed by the die, H, is now compressed, as shown in Fig. 8, the degree of compression being a little short of that made by the preceding die.

The die, K, has its surface covered with a fabric, L, which is stretched over its entire under surface and vertical sides, the means for securing the central portion of the fabric being preferably the plate at which in construction and operation is similar to that described for the plate i. Then the fabric has been compressed by the die, K, said die is removed and the portion depressed thereby has its floor or bottom coated with a nonfibrous substance, as liquid carbon or similar material, and in order that this may be effected without applying the nonfibrous substance, or carbon to other parts, I employ the tool, M, shown in Fig. 9, and which tool may be identical in design and construction with the tool, I, except that the chamber formed in its central portion between the walls 23, is of larger diameter than the corresponding chamber formed in the tool, I, and is of sufficient diameter to inclose the depressed portions formed by the successive operations of the dies, B, H and K.

When the depressed portion made by the die, K, has been supplied with the carbon or non-fibrous material, the tool, M, is removed and the cavity made by the die, K, is filled with loose fibrous material, as shown in Fig. 10. In this figure masses of loose material are shown as occupying all of the former depressions made by the successive dies; the carbon coated surfaces are clearly indicated at 10, 11 and 12 in said figure. I now subject the material to a final compression and to this end I employ a die substantially of the form shown at, N, in Fig. 11, which die has a diameter about equal to the interior diameter of the vertical rim, B, and when pressure is applied to the die, N, the mass of material is compressed, as shown in Fig. 11 with the result that a pad or disk of asbestos or fibrous material is produced having zones carbonated at different points and with the carded asbestos so placed that it covers, in each instance, a newly carbonated area thickly and an uncarbonated area lightly. In other words, a filtering medium of the form shown in Fig. 12 is produced, this medium consisting in compressed, alternate layers of carded asbestos and layers of nonfibrous material as carbon, and wherein the layers of non-fibrous material are interstratified with the asbestos, or fibrous material, the fibers of the felt or asbestos interlocking to hold the carbon-coated or non-fibrous portions in place.

Having thus described my invention what I claim as new and desire to secure by Letters Patent is 1. In an apparatus for making a felt or filtering medium, the combination with a lower die having a reduced upwardly projecting central portion with a horizontal shoulder at the base thereof, of a vertical rim surrounding the reduced portion of the die and extending thereabove, said rim having a lower edge removably supported on the die and said rim forming a holder for a mass of fibrous material, and a fibrous covering extending over the upper surface of the projecting central portion of the die and over the vertical side thereof and fixed to said vertical side, and frictionally engaged by the vertical inner wall of the rim.

2. In an apparatus for making a felt or filtering medium, the combination with a lower die having a reduced upwardly projecting central portion forming a shoulder at an intermediate portion of the die, of a vertical rim inclosing the reduced portion of the die having its inner wall frictionally engaging and inclosing the outer wall of said reduced portion, and having its lower edge supported on said shoulder, said rim inclosing a chamber adapted to contain a mass of fibrous material, and said die having an'absorbent fabric closely applied to its surface and extending over the edge thereof and frictionally engaged by the innor wall of the rim.

3. In an apparatus for making a felt or filtering medium, the combination with a die composed of metal and an inclosed core said die having an upper portion of reduced diameter with a shoulder at the base of the same; a fabric extending over the upper face of the die, means for securing the edge portion of the fabric to the die, and a detachable rim inclosing the reduced portion of the die and extending thereabove and forming a container for a mass of fibrous material.

4. In an apparatus for making a felt or filtering medium, the combination with a die having a shoulder and a detachable rim resting upon said shoulder and extending vertically above the die, and forming a con tainer for a mass of fibrous material, of a fabric extending over the upper face of the die and over the edge thereof, said die hav ing annular grooves in its side and cords encircling the die and adapted to draw por tions of the fabric into the grooves to secure the fabric to the die and to stretch said fabric evenly over the face of said die.

In an apparatus for making a felt or filtering medium, the combination with a lower die and a rim surrounding the same and extending thereabove and adapted as a container for a mass of fibrous material, of an upper die having a central projection on its underside fitting within and frictionally engaging the inner wall of the rim, and adapted to compress the central portion only of said mass of material and form a recess therein while leaving the greater portion of the mass of material uncompressed.

6. In an apparatus for making a felt or filtering medium, the combination with a lower die and a rim surrounding the same and extending thereabove and adapted as a container for a mass of fibrous material, said rim closely fitting over the central portion of the die and forming a tight joint around the upper edge of the die, of an upper die having a central projection on its under side of less diameter than the rim and adapted to compress the central portion only of said mass of material and form a recess therein, said dies having absorbent fabric closely applied to their surfaces, and said rim being separably mounted on the lower die.

7. In an apparatus for making a felt or filtering medium, the combination with a lower die and a rim surrounding the same and extending thereabove and adapted as a container for a mass of fibrous material, of an upper die having a central projection on its under side of less diameter than the die, and adapted to compress the central portion only of said mass of material and form a recess therein, and a tool of tubular form having a diameter approximating that of said depression and adapted to fit the depression and protect the walls thereof, said tool being open at both ends to afford access to the bottom of the depression for a coating of non-fibrous material.

8. In an apparatus for making a felt or filtering medium, the combination with a container for a mass of fibrous material, of a die adapted to enter the container having a central projection on its under side adapted to compress a minor portion only of said mass of material and produce a cavity therein while leaving the balance and major of the material substantially undisturbed.

9. In an apparatus for making a felt or filtering medium, the combination with a container for a mass of fibrous material, of a die adapted to enter the container having a central projection on its under side adapted to compress a portion only of said mass of material and produce a cavity therein while leaving the balance of the material substantially undisturbed, and an open-ended tool of tubular form having adiameter approximating that of the central projection of the die and adapted to occupy said cavity when the latter is removed, and to expose the bottom of said cavity and admit thereto a coating of non-fibrous material.

10. In an apparatus for making a felt or filtering medium, the combination with a container for a mass of fibrous material and means for producing a cavity in the central portion of said material, of a die adapted to enter said container having a central cavity in its under surface substantially co-extensive with the cavity formed in the mass of material, said die having a projecting portion circumscribing its cavity andadapted to compress an area of the mass of fibrous material exterior to and surrounding the central cavity.

11. In an apparatus for making a felt or filtering medium, the combination with a container for a mass of fibrous material, of a die adapted to enter said container having a central cavity in its under surface and having a projecting portion circumscribing the cavity and adapted to compress an area of the mass of fibrous material intermediate of the center and outer edge thereof.

12. In an apparatus for making a felt or filtering medium, the combination with a container for a mass of fibrous material, of a die adapted to enter said container having a central cavity in its under surface to include a prescribed portion of the center of said mass, said die having a projecting portion inclosing and circumscribing its cavity and adapted to compress an area of said mass of fibrous material exterior to and surrotmding the center of the mass, to form a depressed chamber in an intermediate portion of said material.

13. In an apparatus for making a felt or filtering medium, the combination with a container for a mass of fibrous material, of a die adapted to enter said container having a central cavity in its under surface to include a prescribed portion of the center of said mass, said die having a projecting portion inclosing and circumscribing its cavity and adapted to compress an area of said mass of fibrous material exterior to and surrounding the center of the mass, to form a depressed chamber in an intermediate portion of said material, and a tool having separated inner and outer walls, corresponding to and adapted to substantially fit and cover the corresponding Walls of the depressed por tion, said tool being open at the bottom and top to permit the bottom of the depressed portion to be supplied with a non-fibrous coating.

14. In an apparatus for making a felt or filtering medium, the combination with a container for a mass of fibrous material, of a die adapted to enter said container and having a projecting portion around its outer edge adapted to compress the outer edge portion of the fibrous material, said die having a cavity adapted to inclose and leave substantially undisturbed the portion of fibrous material intermediate of the inner walls of the said cavity.

15. In an apparatus for making a felt or filtering medium, the combination with a container for a mass of fibrous material, of a die adapted to enter said container and having a projecting portion around its outer edge adapted to compress the outer edge portion of the fibrous material, said die having a cavity adapted to inclose and leave substantially undisturbed the portion of fibrous material intermediate of the inner walls of the said cavity, and a tool having separated inner and outer walls and adapted to occupy the portion depressed by said die, said tool having a cavity intermediate of the inner walls adapted to inclose and receive loose and uncompressed fibrous material occupying a central portion of the mass, and said tool being open at top and bottom to permit the depressed portion around the outer edge of the mass to be supplied with a non-fibrous coating.

16. In an apparatus for making a felt or filtering medium, the combination with a container for a mass of fibrous material, of means for producing a cavity in a prescribed portion of said material, said means including a die having a portion projecting from its under surface and said die having a cavity in its under surface; a sheet of fabric pressed into said cavity, a securing plate fitting the cavity and securing the fabric to the die, said fabric being stretched under tension over the projecting portion of the die, and means for securing the outer edge of the fabric to said die.

17 In an apparatus for making a felt or filtering medium, the combination with a container for a mass of fibrous material, of a series of dies adapted to produce cavities successively in difierent areas of said mass, tools conforming to the cavities made by said dies and permitting the floors of the depressed portions to be supplied with a nonfibrous coating without disturbing portions of adjacent areas, said tools being of successively increasing diameters, and said dies having projections of corresponding successively increasing diameters, each of the dies having a common exterior diameter and one which proximates the inner diameter of the container, said dies having their surfaces provided with a moisture-retaining fabric.

In testimony whereof I affix my signature in presence of two Witnesses.

EDWARD M. KNIGHT.

Witnesses:

L. KNIGHT, T. W. FOWLER. 

